During the operation of the OTC DAIHEN Welding Robot, if the system experiences problems such as contact detection point exception, adaptive EN ratio over limit, restart failure, or weaving trajectory exceeding the specified speed, the teach pendant will usually display a hardware and control-level alarm in the 5421 to 6006 range. If these faults are not investigated promptly, they may cause serious operational safety hazards or damage to core components such as the reducer.
To help on-site engineers and mechanics quickly locate problems, we have organized the diagnostic terminology from the official maintenance manual to provide you with the following intuitive fault quick reference table. We recommend using the search function, entering the error code (e.g., 5421), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (5421-6006)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 5421 | Contact Detection Point Exception | The final command position is too far from the detected contact signal. | Contact our service department, back up the files to an external CF memory card, and turn on the control power again. |
| 5422 | Adaptive EN Ratio Too Large | The EN ratio specified by adaptive control exceeds the maximum EN ratio display value of adaptive control. | Check the data table via WinUser, increase the maximum EN ratio display for adaptive control, and then reset. |
| 5423 | Adaptive EN Ratio Insufficient | The EN ratio specified by adaptive control is lower than the minimum EN ratio display value of adaptive control. | Check the data table via WinUser, decrease the minimum EN ratio display for adaptive control, and then reset. |
| 5424 | EN Ratio Monitoring Range Setting Exception | An exception occurs when the minimum value of EN ratio monitoring exceeds the maximum value set in the adaptive control state. | Check the minimum and maximum values of the EN ratio monitoring value, and then reset the fault. |
| 5425 | Line Speed Monitoring Range Setting Exception | An exception occurs when the minimum value of the line speed monitoring value exceeds the maximum value set in the adaptive control state. | Check the minimum and maximum values of the line speed monitoring value, and then reset the fault. |
| 5701 | Option Not Set | This error occurs when using an unset option function. | The option should be set, no reset operation is required. |
| 5702 | Cannot Restart | Cannot move to the return position or restore the section status. | Restart after setting the step sequence outside the section, no reset operation is required. |
| 5703 | Input and Output Signals Not Set | An exception occurs when input and output signals are not set. | Set the input and output signals, and then reset the fault. |
| 6005 | Weaving Trajectory Exceeds Specified Speed | Because the movement amount of the weaving pattern data is too large or the frequency (speed) is too high, the speed exceeds the specified speed. | The weaving movement amount or frequency (speed) should be modified, no reset operation is required. |
| 6006 | Teaching Weaving Posture Variation Exceeds Limit | The posture variation of the weaving pattern data is too large. | The posture variation of the teaching weaving pattern data should be modified, no reset operation is required. |
II. Get Professional Technical Support and Maintenance Services
When the robot frequently displays the above hardware-level alarms, and routine reset attempts are ineffective, do not forcefully pull the robot arm or repeatedly force restarts, so as not to cause secondary irreversible damage.
Contact Anhui Oujie for Technical Guidance
- System Recovery & Hardware Repair: Manager Fang
- Service Hotline (WhatsApp): 180-9663-1656
- Official Email: ahojotc@gmail.com
If you do not know how to handle such underlying alarms on-site, please take a picture of the error screen on the teach pendant and the on-site status, and send it to us via WhatsApp. As an OTC Designated Authorized Distributor, our professional maintenance engineers will provide you with a free technical assessment and troubleshooting solution!